JP2007209996A - Method for producing ventilated type disk rotor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To suppress uneven abrasion of a ventilated type disk rotor. <P>SOLUTION: The ventilated type disk rotor having a plurality of fins is produced using a mold 100 provided with: an upper mold 50; a lower mold 52; and a core 54 having a plurality of fin cavities 62 for forming a plurality of the fins. In the core 54, a part of the fin cavities 62a provided at prescribed intervals among the plurality of fin cavities 62 is formed so as to be wider in a circumferential direction than the other fin cavities 62. The prescribed position of the mold 100 is provided with a weir 102 for pouring molten metal into the cavities of the mold 10, and the core 54 is arranged in such a manner that the widely formed fin cavities 62a are located in the vicinity of the weir 102 so as to perform casting. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a ventilated disc rotor used in a vehicle disc brake device.

  Conventionally, ventilated disk rotors are known as disk rotors used in vehicle disk brake devices. In order to improve the cooling performance of the disk rotor, a plurality of ventilation holes penetrating from the inner circumference side to the outer circumference side of the disk rotor are formed.

  When such a ventilated disc rotor rotates, the air in the ventilation hole is discharged to the outside from the outer peripheral side opening by centrifugal force. As a result, the inside of the ventilation hole is in a negative pressure state, and external air is taken in from the inner peripheral side opening of the ventilation hole, whereby an air flow is created in the disk rotor, and the disk rotor can be cooled.

As a method for manufacturing such a ventilated type disk rotor, Patent Document 1 discloses a method using a mold having a cavity, a weir, and a runner.
JP 2004-344944 A

  However, in the method of manufacturing the disk rotor by casting, it is difficult from the viewpoint of productivity and cost to make the cooling rate of the molten metal completely uniform over the entire circumference of the disk rotor. Therefore, a difference in metal structure due to a difference in cooling rate is inevitably generated in the disk rotor. A portion where the cooling rate of the molten metal is fast is increased in rigidity because the metal structure is refined, whereas a portion where the cooling rate is low is decreased in rigidity. When the brake operation of pressing the brake pad against the disc rotor with such a partial difference in rigidity is repeated, uneven wear occurs, and thick and thin portions are formed in the circumferential direction on the disc rotor. There was a problem of vibration.

  This invention is made | formed in view of such a condition, The objective is to provide the technique which can suppress the partial wear of a ventilated type disk rotor.

  In order to solve the above-described problem, a method for manufacturing a ventilated disk rotor according to an aspect of the present invention provides a ventilated disk rotor having a plurality of fins by injecting molten metal from a plurality of weirs into a mold. In the manufacturing method, the fin located in the vicinity of the weir is formed wider in the circumferential direction or longer in the radial direction than the fin located in a region other than the vicinity of the weir.

  When manufacturing a disk rotor by casting, the part of the disk rotor in the vicinity of the weir becomes soft because the cooling rate is slow. According to this aspect, the fins located in the vicinity of the weir are formed wider in the circumferential direction or longer in the radial direction than the fins located in the region other than the vicinity of the weir, so that the rigidity of the portion of the disk rotor near the weir is increased. be able to. The difference in rigidity between the disk rotor part near the weir and the disk rotor part other than the weir is smaller than when the disk rotor is manufactured with the circumferential width or radial length of the fins uniform. Therefore, uneven wear occurring in the disk rotor can be suppressed.

  Another embodiment of the present invention is also a method for manufacturing a ventilated disk rotor. This method is a method of manufacturing a ventilated disk rotor having a plurality of fins by injecting molten metal into a mold from a plurality of weirs, and the interval between fins located in the vicinity of the weir It is narrower than the interval between the fins located in the other region.

  According to this aspect, since the interval between the fins located in the vicinity of the weir is formed narrower than the interval between the fins located in the region other than the vicinity of the weir, the rigidity of the portion of the disk rotor near the weir can be increased. The difference in rigidity between the disk rotor part near the weir and the disk rotor part other than the weir can be made smaller than the case where the disk rotor is manufactured with the same gap between the fins. Uneven wear can be suppressed.

  Yet another embodiment of the present invention is also a method for manufacturing a ventilated disc rotor. In this method, a ventilated type disk rotor having a plurality of fins, a mold having an upper mold, a lower mold, and a core having a plurality of fin cavities for forming the plurality of fins are used. In the manufacturing method, the core is formed such that some of the fin cavities provided at predetermined intervals in the circumferential direction are wider in the circumferential direction or longer in the radial direction than the other fin cavities. A weir for injecting molten metal into the mold cavity is arranged at a predetermined position of the mold so that the fin cavity formed wide in the circumferential direction or long in the radial direction is positioned in the vicinity of the weir. Place the core and cast.

  Even in this embodiment, the difference in rigidity between the disk rotor portion in the vicinity of the weir and the other disk rotor portions is compared with the case where the disk rotor is manufactured with the circumferential width or radial length of the fins uniform. Therefore, uneven wear that occurs in the disk rotor can be suppressed.

  Yet another embodiment of the present invention is also a method for manufacturing a ventilated disc rotor. In this method, a ventilated disk rotor having a plurality of fins, a mold having an upper mold, a lower mold, and a core having a plurality of fin cavities for forming the plurality of fins are used. The core is formed such that the fin cavity interval in a predetermined region in the circumferential direction is narrower than the fin cavity interval in other regions, and the core is located at a predetermined position of the mold. A weir for injecting molten metal into the cavity is disposed, and the core is disposed and cast so that the region where the fin cavity interval is narrow is located in the vicinity of the weir.

  Also according to this aspect, the difference in rigidity between the disk rotor portion near the weir and the other disk rotor portions can be made smaller than that in the case where the disk rotor is manufactured with uniform fin intervals. Uneven wear generated in the rotor can be suppressed.

  According to the present invention, uneven wear of the ventilated disk rotor can be suppressed.

  FIG. 1 is a partially cutaway front view of a disk rotor casting mold 100 according to the present embodiment. FIG. 2 is an XX cross-sectional view of the mold 100 shown in FIG. 3 is a YY cross-sectional view of the mold 100 shown in FIG. The mold 100 shown in FIGS. 1 to 3 includes an outer side sliding plate disposed on the outer side in the vehicle width direction, and an inner side disposed on the inner side in the vehicle width direction so as to be parallel to the outer side sliding plate. A ventilator comprising a sliding plate, a plurality of fins that are radially formed between the outer side sliding plate and the inner side sliding plate, and that couples the two, and a hat portion that is used when attached to the axle. This is a mold for casting a Ted type disk rotor.

  As shown in FIGS. 1 to 3, the mold 100 includes an upper mold 50, a lower mold 52, and a core 54. As shown in FIGS. 2 and 3, an outer side sliding plate cavity 60 for forming the outer side sliding plate and a hat portion cavity 64 for forming the hat portion are formed in the lower portion of the upper mold 50. ing. An inner side sliding plate cavity 58 for forming an inner side sliding plate is formed in the upper part of the lower mold 52. The core 54 is formed with fin cavities 62 for forming a plurality of radial fins. As shown in FIG. 1, 24 fin cavities 62 are formed in the circumferential direction of the core 54 so as to be spaced apart at substantially equal intervals (360/24 = 15 degrees). Hereinafter, the inner side sliding plate cavity 58, the outer side sliding plate cavity 60, the fin cavity 62, and the hat portion cavity 64 are collectively referred to as “cavity”.

  The weir 102 plays a role of communicating a runner (not shown) and a cavity. As shown in FIG. 1, four weirs 102 are arranged at intervals of 90 degrees in the circumferential direction in the mold 100 according to the present embodiment. In the mold 100, a region near the weir 102 is called a weir front portion 108. FIG. 2 shows a cross-sectional view of the weir front 108. The region in the vicinity of the weir 102 is a region having at least the width of the weir 102 in the circumferential direction and the length of the fin cavity 62a in the radial direction. The molten metal is poured directly into the cavity of the weir front part 108 from the weir 102. Since the four dams 102 are arranged in the mold 100 according to the present embodiment, there are four dam front portions 108. Further, a region other than the weir front portion 108, that is, a region other than the vicinity of the weir 102 is referred to as an inter-weir portion 110. FIG. 3 shows a cross-sectional view of the interweir portion 110. The cavity of the inter-weir part 110 is supplied with molten metal via the front part 108 of the weir.

  When molten metal is poured into the mold 100 configured in this manner from a gate (not shown), the molten metal reaches the four weirs 102 via the runners. Then, the molten metal flows into the inner sliding plate cavity 58 through the weir 102 and is finally filled in the entire cavity. Thereafter, the mold 100 is cooled to solidify the molten metal, and the solidified product is taken out from the mold 100 to obtain a disk rotor.

  In the mold 100 according to the present embodiment, as shown in FIG. 1, four fin cavities 62a provided at intervals of 90 degrees out of the 24 fin cavities 62 formed in the core 54 have other fins. It is formed wider than the cavity 62 in the circumferential direction. Then, casting is performed in a state in which the core 54 is disposed so that the fin cavity 62 a formed to be wide is positioned at the dam front portion 108. Thus, by forming and arranging the core 54 and performing casting, the difference in partial rigidity of the disk rotor can be reduced, and uneven wear can be suppressed.

  The weir front part 108 is less cooled than the inter-weir part 110 because the molten metal is poured from the weir 102 one after another, and the inter-weir part 110 has a relatively faster cooling rate than the front weir part 108. The portion of the disk rotor corresponding to the cavity of the inter-weir section 110 where the molten metal cooling rate is fast (hereinafter referred to as the inter-weir portion as appropriate) becomes hard because the metal structure is refined, but the weir with the slow cooling rate is conversely The part of the disk rotor corresponding to the cavity of the front part 108 (hereinafter referred to as the pre-weir part as appropriate) becomes soft. For this reason, when the disk rotor is manufactured with the circumferential width of the fins made uniform, the rigidity becomes low at the front part of the weir and the rigidity becomes high at the part between the weirs. When there is a partial rigidity difference in the disk rotor in this way, uneven wear occurs in the disk rotor when the operation of pressing the brake pad against the disk rotor is repeated.

  In the disk rotor manufactured by the mold 100 according to the present embodiment, the fin in the front part of the weir is wider in the circumferential direction than the fin in the part between the weirs, so that the rigidity of the front part of the weir is increased. . Since the difference in rigidity between the front part of the weir and the part between the weirs is smaller than that in the case of manufacturing the disk rotor with the circumferential width of the fins uniform, it is possible to suppress uneven wear that occurs in the disk rotor. it can.

  Further, the disk rotor manufactured by the mold 100 according to the present embodiment only changes the shape of the fin located between the sliding plates, so there is no need to change the structure of the disk brake device itself, It can be easily applied to existing disc brake devices.

  FIG. 4 is a partially broken front view of a modification of the disk rotor casting mold according to the present embodiment. The mold 200 shown in FIG. 4 is different from the core 54 shown in FIG. In addition, the same code | symbol is used about the component same as the casting_mold | template 100 shown in FIG.

  The core 202 according to this modification is formed such that the interval between the fin cavities 204 in a region of a predetermined interval (interval of 90 degrees) in the circumferential direction is narrower than the interval between the fin cavities 204 in other regions. Then, the core 202 is placed and cast so that the region where the interval between the fin cavities 204 is narrow is located in the vicinity of the weir 102.

  When casting is performed by forming and arranging the core 202 in this way, the fin interval is narrow in the portion between the weirs of the manufactured disc rotor. Therefore, the disc rotor manufactured with uniform fin intervals is used. Rigidity is higher than the part between the weirs. As a result, the difference in rigidity between the pre-weir part and the inter-weir part of the disk rotor can be reduced, so that uneven wear occurring in the disk rotor can be suppressed.

  The present invention has been described above based on the embodiment. It should be understood by those skilled in the art that these embodiments are exemplifications, and that various modifications can be made to the combination of each component and each processing process, and such modifications are also within the scope of the present invention.

  For example, in the above-described embodiment, the number of fin cavities is 24, but the number of fin cavities is not limited to this. In the embodiment, the weirs are arranged at intervals of 90 degrees. However, the present invention is not limited to this, and the weirs may be arranged at arbitrary intervals. In the embodiment, the molten metal is injected from the outer peripheral side of the mold. However, the molten metal may be injected from the inner peripheral side of the mold.

  In the embodiment, the fins in the front part of the weir are formed wider in the circumferential direction than the fins in the part between the weirs, but the fins in the front part of the weir are formed longer in the radial direction than the fins in the part between the weirs. As a result, the difference in rigidity between the pre-weir part and the inter-weir part can be reduced, and uneven wear can be suppressed.

It is a partially broken front view of the disk rotor casting mold according to the present embodiment. It is XX sectional drawing of the casting_mold | template shown in FIG. It is YY sectional drawing of the casting_mold | template shown in FIG. It is a partially broken front view of the modification of the casting mold for disk rotor casting concerning this embodiment.

Explanation of symbols

  50 Upper mold, 52 Lower mold, 54, 202 Core, 58 Inner side sliding plate cavity, 60 Outer side sliding plate cavity, 62, 204 Fin cavity, 64 Hat cavity, 100, 200 Mold, 102 Weir, 108 The front part of the weir, 110 The part between the weirs.

Claims (4)

A method of manufacturing a ventilated disc rotor having a plurality of fins by injecting molten metal from a plurality of weirs into a mold,
A method of manufacturing a ventilated disc rotor, wherein the fins located in the vicinity of the weir are formed wider in the circumferential direction or longer in the radial direction than the fins located in a region other than the vicinity of the weir. A method of manufacturing a ventilated disk rotor having a plurality of fins by injecting molten metal into a mold from a plurality of weirs,
A method for manufacturing a ventilated disk rotor, characterized in that an interval between fins located in the vicinity of the weir is narrower than an interval between fins located in a region other than the vicinity of the weir. A method of manufacturing a ventilated disc rotor having a plurality of fins using a mold comprising an upper die, a lower die, and a core having a plurality of fin cavities for forming the plurality of fins. Because
In the core, a part of the plurality of fin cavities provided at predetermined intervals in the circumferential direction are formed wider in the circumferential direction or longer in the radial direction than the other fin cavities,
Place a weir for pouring molten metal into the mold cavity at a predetermined position of the mold,
A manufacturing method of a ventilated type disk rotor, wherein a core is arranged and cast so that a fin cavity formed wide in a circumferential direction or long in a radial direction is positioned in the vicinity of the weir. A ventilated disc rotor having a plurality of fins is manufactured using a mold including an upper die, a lower die, and a core having a plurality of fin cavities for forming the plurality of fins. A method,
The core is formed such that the fin cavity interval in the region of the predetermined interval in the circumferential direction is narrower than the fin cavity interval in the other region,
Place a weir for pouring molten metal into the mold cavity at a predetermined position of the mold,
A method for manufacturing a ventilated type disk rotor, wherein the core is disposed and cast so that the region where the fin cavity interval is narrow is located in the vicinity of the weir.

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